Compositions in the form of dissolvable solid structures

ABSTRACT

Described are effervescent dissolvable solid structures having fibers formed from a composition comprising surfactant and water soluble polymeric structurant, having a total dissolvable solid structure density of from about 0.100 g/cm 3 to about 0.380 g/cm 3 , having a surfactant dose of from about 0.5 to about 2.0 g, and a surfactant density of from about 0.1 g/cm 3  to about 0.3 g/cm 3 . Also described are processes for manufacturing the Dissolvable Solid Structure.

FIELD OF THE INVENTION

The present invention relates to compositions in the form of dissolvablesolid structures.

The dissolvable solid structures comprise fibers formed from acomposition comprising a surfactant and a water soluble polymericstructurant wherein the dissolvable solid structure has a bulk densityof less than about 0.380 g/cm³, a surfactant dose of from about 0.5 g toabout 2.0 grams, and a surfactant density of from about 0.1 g/cm³ toabout 0.3 g/cm³.

BACKGROUND OF THE INVENTION

Many personal care and other consumer products in the market today aresold in liquid form. While widely used, liquid products often havetradeoffs in terms of packaging, storage, transportation, andconvenience of use. Liquid consumer products typically are sold inbottles which add cost as well as packaging waste, much of which ends upin land-fills.

Dissolvable solid products have been disclosed, comprising awater-soluble polymeric structurant and a surfactant or otheringredients. Although existing dissolvable products provide goodperformance benefits to end users, the processes for making them canhave less than optimal cost, rate of manufacture, and/or productvariability parameters.

The inventors surprisingly found that it is possible to deliver 1)sufficient cleansing in a unit-dose article that 2) readily dissolves inwater, and 3) fits in a typical consumer hand. These benefits areachieved when a dissolvable solid structures comprises fibers formedfrom a composition comprising a surfactant and a water soluble polymericstructurant, wherein the dissolvable solid structure has a bulk densityof less than about 0.380 g/cm³, a surfactant dose of from about 0.5 g toabout 2.0 grams, and a surfactant density of from about 0.1 g/cm³ toabout 0.3 g/cm³.

SUMMARY OF THE INVENTION

A dissolvable solid structure comprising fibers wherein the fibers areformed from a composition comprising: from about 10% to about 75% of asurfactant; from about 10% to about 70% water soluble polymericstructurant; wherein the dissolvable solid structure comprises adetersive surfactant from about 0.5 g to about 4.0 g, has a detersivesurfactant density from about 0.1 to about 0.3 g/cm³; the bulk densityof the dissolvable solid structure is from about 0.100 to about 0.380g/cm³, the dissolvable solid structure weight is from about 1.0 g toabout 4.0 g, and wherein the footprint of the dissolvable solidstructure is from about 1 cm² to about 50 cm².

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic representation of an example of a fibrous elementaccording to the present invention;

FIG. 2 is a schematic representation of an example of a fibrousstructure according to the present invention;

FIG. 3A is a microCT image of an example of a fibrous structurecomprising apertures according to the present invention;

FIG. 3B is a partial, perspective view of the image of FIG. 3A;

FIG. 3C is a cross-sectional view of the image of FIG. 3B;

FIG. 4 is a microCT image of another example of a fibrous structurecomprising apertures according to the present invention;

FIG. 5 is a microCT image of another example of a fibrous structurecomprising apertures according to the present invention;

FIG. 6 is a microCT image of another example of a fibrous structurecomprising apertures according to the present invention;

FIG. 7 is a schematic representation of an example of a process formaking fibrous elements of the present invention;

FIG. 8 is a schematic representation of an example of a die with amagnified view used in the process of FIG. 7;

FIG. 9 is a schematic representation of an aperturing process accordingto the present invention;

FIG. 10A is a perspective view of an example of a portion of a rotaryknife aperturing apparatus;

FIG. 10B is a top view of a portion of FIG. 10A;

FIG. 10C is a front view of FIG. 10A;

FIG. 10D is a side view of FIG. 10A;

FIG. 11A is a perspective view of an example of a pinning aperturingapparatus;

FIG. 11B is a top view of FIG. 11A;

FIG. 11C is a side view of FIG. 11A;

FIG. 12 is a front view of an example of a setup of equipment used inmeasuring dissolution according to the present invention;

FIG. 13 is a side view of FIG. 12;

FIG. 14 is a partial top view of FIG. 12.

DETAILED DESCRIPTION OF THE INVENTION

A. Definitions

As used herein, The Dissolvable Solid Structure may be referred toherein as “the Dissolvable Solid Structure”, “the Structure”, or “theDissolvable Structure”.

As used herein, “dissolvable” means that the Dissolvable Solid Structuremeets the hand dissolution values discussed herein. The DissolvableSolid Structure has a hand dissolution value of from about 1 to about 30strokes, alternatively from about 2 to about 25 strokes, alternativelyfrom about 3 to about 20 strokes, and alternatively from about 4 toabout 15 strokes, as measured by the Hand Dissolution Method.

As used herein, “flexible” means a Dissolvable Solid Structure meets thedistance to maximum force values discussed herein.

“Fibrous structure” as used herein means a structure that comprises oneor more fibrous elements and optionally, one or more particles. In oneexample, a fibrous structure according to the present invention means anassociation of fibrous elements and optionally, particles that togetherform a structure, such as a unitary structure, capable of performing afunction.

The fibrous structures of the present invention may be homogeneous ormay be layered. If layered, the fibrous structures may comprise at leasttwo and/or at least three and/or at least four and/or at least fivelayers, for example one or more fibrous element layers, one or moreparticle layers and/or one or more fibrous element/particle mixturelayers. A layer may comprise a particle layer within the fibrousstructure or between fibrous element layers within a fibrous structure.A layer comprising fibrous elements may sometimes be referred to as aply. A ply may be a fibrous structure which may be homogeneous orlayered as described herein.

In one example, a single-ply fibrous structure according to the presentinvention or a multi-ply fibrous structure comprising one or morefibrous structure plies according to the present invention may exhibit abasis weight of less than 1800 g/m² as measured according to the BasisWeight Test Method described herein. In one example, the single- ormulti-ply fibrous structure according to the present invention mayexhibit a basis weight of greater than 10 g/m² to about 1800 g/m² and/orgreater than 10 g/m² to about 1750 g/m² and/or greater than 500 g/m² toabout 1800 g/m² as measured according to the Basis Weight Test Method.

In one example, the fibrous structure of the present invention is a“unitary fibrous structure.”

“Unitary fibrous structure” as used herein is an arrangement comprisinga plurality of two or more and/or three or more fibrous elements thatare inter-entangled or otherwise associated with one another to form afibrous structure and/or fibrous structure plies. A unitary fibrousstructure of the present invention may be one or more plies within amulti-ply fibrous structure. In one example, a unitary fibrous structureof the present invention may comprise three or more different fibrouselements. In another example, a unitary fibrous structure of the presentinvention may comprise two or more different fibrous elements.

“Article” as used herein refers to a consumer use unit, a consumer unitdose unit, a consumer use saleable unit, a single dose unit, or otheruse form comprising a unitary fibrous structure and/or comprising one ormore fibrous structures of the present invention.

“Fibrous element” as used herein means an elongate particulate having alength greatly exceeding its average diameter, i.e. a length to averagediameter ratio of at least about 10. A fibrous element may be a filamentor a fiber. In one example, the fibrous element is a single fibrouselement rather than a yarn comprising a plurality of fibrous elements.

The fibrous elements of the present invention may be spun from afilament-forming compositions also referred to as fibrouselement-forming compositions via suitable spinning process operations,such as meltblowing, spunbonding, electro-spinning, and/or rotaryspinning.

The fibrous elements of the present invention may be monocomponent(single, unitary solid piece rather than two different parts, like acore/sheath bicomponent) and/or multicomponent. For example, the fibrouselements may comprise bicomponent fibers and/or filaments. Thebicomponent fibers and/or filaments may be in any form, such asside-by-side, core and sheath, islands-in-the-sea and the like.

“Filament” as used herein means an elongate particulate as describedabove that exhibits a length of greater than or equal to 5.08 cm (2 in.)and/or greater than or equal to 7.62 cm (3 in.) and/or greater than orequal to 10.16 cm (4 in.) and/or greater than or equal to 15.24 cm (6in.).

Filaments are typically considered continuous or substantiallycontinuous in nature. Filaments are relatively longer than fibers.Non-limiting examples of filaments include meltblown and/or spunbondfilaments. Non-limiting examples of polymers that can be spun intofilaments include natural polymers, such as starch, starch derivatives,cellulose, such as rayon and/or lyocell, and cellulose derivatives,hemicellulose, hemicellulose derivatives, and synthetic polymersincluding, but not limited to polyvinyl alcohol and also thermoplasticpolymer filaments, such as polyesters, nylons, polyolefins such aspolypropylene filaments, polyethylene filaments, and biodegradablethermoplastic fibers such as polylactic acid filaments,polyhydroxyalkanoate filaments, polyesteramide filaments andpolycaprolactone filaments.

“Fiber” as used herein means an elongate particulate as described abovethat exhibits a length of less than 5.08 cm (2 in.) and/or less than3.81 cm (1.5 in.) and/or less than 2.54 cm (1 in.).

Fibers are typically considered discontinuous in nature. Non-limitingexamples of fibers include staple fibers produced by spinning a filamentor filament tow of the present invention and then cutting the filamentor filament tow into segments of less than 5.08 cm (2 in.) thusproducing fibers.

In one example, one or more fibers may be formed from a filament of thepresent invention, such as when the filaments are cut to shorter lengths(such as less than 5.08 cm in length). Thus, in one example, the presentinvention also includes a fiber made from a filament of the presentinvention, such as a fiber comprising one or more filament-formingmaterials and one or more additives, such as active agents. Therefore,references to filament and/or filaments of the present invention hereinalso include fibers made from such filament and/or filaments unlessotherwise noted. Fibers are typically considered discontinuous in naturerelative to filaments, which are considered continuous in nature.

“Filament-forming composition” and/or “fibrous element-formingcomposition” as used herein means a composition that is suitable formaking a fibrous element of the present invention such as by meltblowingand/or spunbonding. The filament-forming composition comprises one ormore filament-forming materials that exhibit properties that make themsuitable for spinning into a fibrous element. In one example, thefilament-forming material comprises a polymer. In addition to one ormore filament-forming materials, the filament-forming composition maycomprise one or more additives, for example one or more active agents.In addition, the filament-forming composition may comprise one or morepolar solvents, such as water, into which one or more, for example all,of the filament-forming materials and/or one or more, for example all,of the active agents are dissolved and/or dispersed prior to spinning afibrous element, such as a filament from the filament-formingcomposition.

In one example as shown in FIG. 1, a fibrous element, for example afilament 10 of the present invention made from a fibrous element-formingcomposition of the present invention is such that one or more additivesfor example one or more active agents, may be present in the filamentrather than on the filament, such as a coating composition comprisingone or more active agents, which may be the same or different from theactive agents in the fibrous elements and/or particles. The total levelof fibrous element-forming materials and total level of active agentspresent in the fibrous element-forming composition may be any suitableamount so long as the fibrous elements of the present invention areproduced therefrom.

In one example, one or more additives, such as active agents, may bepresent in the fibrous element and one or more additional additives,such as active agents, may be present on a surface of the fibrouselement. In another example, a fibrous element of the present inventionmay comprise one or more additives, such as active agents, that arepresent in the fibrous element when originally made, but then bloom to asurface of the fibrous element prior to and/or when exposed toconditions of intended use of the fibrous element.

“Filament-forming material” and/or “fibrous element-forming material” asused herein means a material, such as a polymer or monomers capable ofproducing a polymer that exhibits properties suitable for making afibrous element. In one example, the filament-forming material comprisesone or more substituted polymers such as an anionic, cationic,zwitterionic, and/or nonionic polymer. In another example, the polymermay comprise a hydroxyl polymer, such as a polyvinyl alcohol (“PVOH”), apartially hydrolyzed polyvinyl acetate and/or a polysaccharide, such asstarch and/or a starch derivative, such as an ethoxylated starch and/oracid-thinned starch, carboxymethylcellulose, hydroxypropyl cellulose,hydroxyethyl cellulose. In another example, the polymer may comprisepolyethylenes and/or terephthalates. In yet another example, thefilament-forming material is a polar solvent-soluble material.

The Dissolvable Solid Structure may be referred to herein as “theDissolvable Solid Structure” or “the dissolvable solid structure”, “theDissolvable Structure” or “the Structure”.

As used herein, “vinyl acetate-vinyl alcohol copolymer” (and “copolymer”when used in reference thereto) refers to a polymer of the followingstructure (I):

In structure (I), m and n are integers such that the polymericstructurant has the degree of polymerization and percent alcoholcharacteristics described herein. For purposes of clarity, this use ofthe term “copolymer” is intended to convey that the partially hydrolyzedpolyvinyl acetate of the present invention comprises vinyl alcohol andvinyl acetate units. As discussed below, the polymeric structurant isroutinely prepared by polymerizing vinyl acetate monomer followed byhydrolysis of some of the acetate groups to alcohol groups, as opposedto polymerization of vinyl acetate and vinyl alcohol monomer units (duein-part to the instability of vinyl alcohol).

As used herein a preformed effervescent agglomerated particle(“agglomerated particle”) is an agglomerated particle that containsparticles of both solid carbonate salt and solid acid along with abinder that is prepared prior to incorporation into the fibrous web.

As used herein, “molecular weight” or “M.Wt.” refers to the weightaverage molecular weight unless otherwise stated. Molecular weight ismeasured using industry standard method, gel permeation chromatography(“GPC”).

As used herein, the articles including “a” and “an” when used in aclaim, are understood to mean one or more of what is claimed ordescribed.

As used herein, the terms “include,” “includes,” and “including,” aremeant to be non-limiting.

The methods disclosed in the Test Methods Section of the presentapplication should be used to determine the respective values of theparameters of Applicants' inventions, including those discussed in theDissolvable Structures—Physical Characteristics section below.

All percentages and ratios are calculated by weight unless otherwiseindicated. All percentages and ratios are calculated based on the totalcomposition unless otherwise indicated.

It should be understood that every maximum numerical limitation giventhroughout this specification includes every lower numerical limitation,as if such lower numerical limitations were expressly written herein.Every minimum numerical limitation given throughout this specificationwill include every higher numerical limitation, as if such highernumerical limitations were expressly written herein. Every numericalrange given throughout this specification will include every narrowernumerical range that falls within such broader numerical range, as ifsuch narrower numerical ranges were all expressly written herein.

B. Dissolvable Solid Structure

Hair Care products in the form of a dissolvable solid structure presentan attractive form to consumers. A typical use of these productsincludes a consumer holding the product in her hand, adding water tocreate a solution or dispersion and applying to the hair. In many cases,the products can take a long time to dissolve making it a less enjoyableexperience for the consumer. Therefore, a need exists to havedissolvable solids that exhibit more rapid dissolution. The dissolvablesolid structures are formed from fibers comprising surfactant and watersoluble polymeric structurant. The dissolvable solid structures containfrom about 0.5 g to about 4.0 g of surfactant, and has a detersivesurfactant density of from about 0.1 to about 0.3 g/cm³. The dissolvablesolid structure has a bulk density of from about 0.100 to about 0.380g/cm³, a weight of from about 1.0 g to about 4.0 g and the footprint ofthe dissolvable solid structure is from about 1 cm² to about 50 cm²,alternatively from about 10 cm² to about 50 cm².

The dissolvable solid structure can have a basis weight of from about200/m² grams to about 1800 grams/m², alternatively from about 400 g/m²to about 1,800 g/m², alternatively from about 400 g/m² to about 1750g/m², and alternatively from about 400 g/m² to about 1,650 g/m².

The dissolvable solid structure has a footprint of from about 1 cm² toabout 50 cm², 10 cm² to about 50 cm², alternatively from about 15 cm² toabout 25 cm², alternatively from about 17 cm² to about 23 cm². The bulkdensity of the dissolvable solid structure is from about 0.100 g/cm3 toabout 0.380 g/cm³, alternatively from about 0.100 g/cm³ to about 0.375g/cm³, alternatively from about 0.300 g/cm³ to about 0.375 g/cm³.

The dissolvable solid structure has a hand dissolution value (as definedby the Hand Dissolution Method described herein) of less than about 25strokes, alternatively less than about 15 strokes, alternatively fromabout 5 to about 25 strokes, alternatively from about 1 to about 25strokes, alternatively from about 5 to about 15 strokes.

The dissolvable solid structure may comprise an effervescentagglomerated particle, which can improve dissolution and makes thein-use experience more interesting and enjoyable to the consumer. It hasbeen surprisingly found that the inclusion of effervescent effect issignificantly more pronounced when the effervescent components exist inan agglomerated form in the Dissolvable Solid Structure as compared tothese components added separately and existing in the solid as separateparticles from each other. It was also found that effervescentagglomerated particles and items that contain these agglomeratedparticles can pick up moisture from the environment and reactprematurely, reducing the fast dissolution benefit. It was surprisinglyfound that the inclusion of humectants, such as zeolite, into theeffervescent agglomerated particles prevents this premature reaction.

Dissolvable Structures—Compositional

The dissolvable solid structure can comprise fibers formed from about 3wt % to about 75 wt % surfactant; and from about 10 wt % to about 70 wt% of the polymeric structurant.

The dissolvable solid structure can comprise from about 0.5 g to about4.0 g of surfactant, alternatively from about 0.8 g to about 2.0 gramsof surfactant, alternatively from about 0.9 g to about 1.5 g ofsurfactant, and alternatively from about 1.0 g to about 1.4 g ofsurfactant.

The dissolvable solid structure can comprise from about 1 wt % to about40 wt % preformed effervescent agglomerated particles.

A. Water Soluble Polymeric Structurant

The Dissolvable Solid Structure comprises water-soluble polymers thatfunction as a structurant. As used herein, the term “water-solublepolymer” is broad enough to include both water-soluble andwater-dispersible polymers, and is defined as a polymer with asolubility in water, measured at 25° C., of at least about 0.1gram/liter (g/L). In some embodiments, the polymers have solubility inwater, measured at 25° C., of from about 0.1 gram/liter (g/L). to about500 grams/liter (g/L). (This indicates production of a macroscopicallyisotropic or transparent, colored or colorless solution). The polymersfor making these Dissolvable Solid Structures may be of synthetic ornatural origin and may be modified by means of chemical reactions. Theymay or may not be film-forming. These polymers should be physiologicallyacceptable, i.e., they should be compatible with the skin, mucousmembranes, the hair and the scalp.

The one or more water-soluble polymers may be present from about 5% toabout 70% by weight of the Dissolvable Solid Structure, alternativelyfrom about 15% to about 60% by weight, and alternatively from about 20%to about 50% by weight, and alternatively from about 15% to about 30% byweight.

The one or more water-soluble polymers can be selected such that theirweight average molecular weight is from about 15,000 g/mol to about500,000 g/mol, alternatively from about 50,000 g/mol to about 400,000g/mol, alternatively from about 60,000 g/mol to about 300,000 g/mol, andalternatively from about 70,000 g/mol to about 200,000 g/mol. The weightaverage molecular weight is computed by summing the average molecularweights of each polymer raw material multiplied by their respectiverelative weight percentages by weight of the total weight of polymerspresent within the Dissolvable Solid Structure.

At least one of the one or more water-soluble polymers can be such thatabout 2% by weight solution of the water-soluble polymer gives aviscosity at 20° C. of from about 4 centipoise to about 80 centipoise;alternatively from about 5 centipoise to about 70 centipoise; andalternatively from about 6 centipoise to about 60 centipoise.

The water-soluble polymer(s) can include, but are not limited to,synthetic polymers as described in U.S. Ser. No. 61/120,786 includingpolymers derived from acrylic monomers such as the ethylenicallyunsaturated carboxylic monomers and ethylenically unsaturated monomersas described in U.S. Pat. No. 5,582,786 and EP-A-397410. Thewater-soluble polymer(s) which are suitable may also be selected fromnaturally sourced polymers including those of plant origin exampleswhich are described in U.S. Ser. No. 61/120,786. Modified naturalpolymers are also useful as water-soluble polymer(s) and are included inU.S. Ser. No. 61/120,786. In one embodiment, water-soluble polymersinclude polyvinyl alcohols, polyacrylates, polymethacrylates, copolymersof acrylic acid and methyl acrylate, polyvinylpyrrolidones, polyalkyleneoxides, starch and starch derivatives, pullulan, gelatin,hydroxypropylmethylcelluloses, methycelluloses, andcarboxymethycelluloses. In another embodiment, water-soluble polymersinclude polyvinyl alcohols, and hydroxypropylmethylcelluloses. Suitablepolyvinyl alcohols include those available from Celanese Corporation(Dallas, Tex.) under the CELVOL® trade name. Suitablehydroxypropylmethylcelluloses include those available from the DowChemical Company (Midland, Mich.) under the METHOCEL® trade name.

The above mentioned water-soluble polymer(s) may be blended with anysingle starch or combination of starches as a filler material in such anamount as to reduce the overall level of water-soluble polymers needed,so long as it helps provide the personal care Dissolvable SolidStructure with the requisite structure and physical/chemicalcharacteristics as described herein.

In such instances, the combined weight percentage of the water-solublepolymer(s) and starch-based material generally ranges from about 10% toabout 50%, alternatively from about 15% to about 40%, and alternativelyfrom about 20% to about 30% by weight relative to the total weight ofthe Dissolvable Solid Structure. The weight ratio of the water-solublepolymer(s) to the starch-based material can generally range from about1:10 to about 10:1, alternatively from about 1:8 to about 8:1,alternatively from about 1:7 to about 7:1, and alternatively from about6:1 to about 1:6.

Typical sources for starch-based materials can include cereals, tubers,roots, legumes and fruits. Native sources can include corn, pea, potato,banana, barley, wheat, rice, sago, amaranth, tapioca, arrowroot, canna,sorghum, and waxy or high amylase varieties thereof. The starch-basedmaterials may also include native starches that are modified using anymodification known in the art, including those described in U.S. Ser.No. 61/120,786.

B. Surfactants

The Dissolvable Solid Structure comprises one or more detersivesurfactants suitable for application to the hair or skin. Surfactantssuitable for use in the Structure include anionic surfactants, nonionicsurfactants, cationic surfactants, zwitterionic surfactants, amphotericsurfactants, polymeric surfactants or combinations thereof. Althoughrepresentative surfactants are described herein, the skilled artisanwill recognize that other surfactants can be readily substituted andsimilar benefits can be derived from use of the vinyl acetate-vinylalcohol copolymers described herein. Each patent described throughoutthis application is incorporated herein by reference to the extent eachprovides guidance regarding surfactants suitable for inclusion in theStructure.

In one embodiment, the Structure is a lathering dissolvable solidpersonal care product (dried) and comprises from about 10 wt % to about75 wt % surfactant, in one embodiment from about 25 wt % to about 70 wt% surfactant, in another embodiment from about 40 wt % to about 65 wt %surfactant.

Suitable anionic surfactants include alkyl and alkyl ether sulfates.Other suitable anionic surfactants are the water-soluble salts oforganic, sulfuric acid reaction products. Still other suitable anionicsurfactants are the reaction products of fatty acids esterified withisethionic acid and neutralized with sodium hydroxide. Other similaranionic surfactants are described in U.S. Pat. Nos. 2,486,921;2,486,922; and 2,396,278, which are incorporated herein by reference intheir entirety.

Exemplary anionic surfactants include ammonium lauryl sulfate, ammoniumlaureth sulfate, triethylamine lauryl sulfate, triethylamine laurethsulfate, triethanolamine lauryl sulfate, triethanolamine laurethsulfate, monoethanolamine lauryl sulfate, monoethanolamine laurethsulfate, diethanolamine lauryl sulfate, diethanolamine laureth sulfate,lauric monoglyceride sodium sulfate, sodium lauryl sulfate, sodiumlaureth sulfate, potassium lauryl sulfate, potassium laureth sulfate,sodium lauryl sarcosinate, sodium lauroyl sarcosinate, lauryl sarcosine,cocoyl sarcosine, ammonium cocoyl sulfate, ammonium lauroyl sulfate,sodium cocoyl sulfate, sodium lauroyl sulfate, potassium cocoyl sulfate,potassium lauryl sulfate, triethanolamine lauryl sulfate,triethanolamine lauryl sulfate, monoethanolamine cocoyl sulfate,monoethanolamine lauryl sulfate, sodium tridecyl benzene sulfonate,sodium dodecyl benzene sulfonate, sodium cocoyl isethionate andcombinations thereof. In one embodiment, the anionic surfactant issodium lauryl sulfate or sodium laureth sulfate.

In one embodiment, the anionic surfactant is at least one branchedsulfate having the formulaCH₃—(CH₂)_(z)—CH(R¹)—CH₂—O—(CH₂CH(R²)O)_(y)—SO₃M; where z is from about3 to about 14; R¹ represents H or a hydrocarbon radical comprising 1 to4 carbon atoms, R² is H or CH₃; R¹ and R² are not both H; y is 0 toabout 7; the average value of y is about 1 when y is not=0; and M is amono-valent or di-valent, positively-charged cation. Examples ofmono-valent positively charged cations include ammonium, sodium,potassium, triethanolamine cation, and examples of di-valent positivelycharged cations include magnesium. For the foregoing branched sulfates,“average value” means that whereas the composition may comprisemolecules having a value of y of other than 1, the average value of yall molecules in the composition is about 1.

Suitable amphoteric or zwitterionic surfactants include those which areknown for use in shampoo or other cleansing products. Non limitingexamples of suitable zwitterionic or amphoteric surfactants aredescribed in U.S. Pat. Nos. 5,104,646 and 5,106,609, which areincorporated herein by reference in their entirety.

Suitable amphoteric surfactants include those surfactants broadlydescribed as derivatives of aliphatic secondary and tertiary amines inwhich the aliphatic radical can be straight or branched chain andwherein one of the aliphatic substituents contains from about 8 to about18 carbon atoms and one contains an anionic group such as carboxy,sulfonate, sulfate, phosphate, or phosphonate. Exemplary amphotericdetersive surfactants include cocoamphoacetate, cocoamphodiacetate,lauroamphoacetate, lauroamphodiacetate, and mixtures thereof.

Suitable zwitterionic surfactants include those surfactants broadlydescribed as derivatives of aliphatic quaternaryammonium, phosphonium,and sulfonium compounds, in which the aliphatic radicals can be straightor branched chain, and wherein one of the aliphatic substituentscontains from about 8 to about 18 carbon atoms and one contains ananionic group such as carboxy, sulfonate, sulfate, phosphate orphosphonate. In another embodiment, zwitterionics such as betaines areselected.

Non limiting examples of other anionic, zwitterionic, amphoteric oroptional additional surfactants suitable for use in the compositions aredescribed in McCutcheon's, Emulsifiers and Detergents, 1989 Annual,published by M. C. Publishing Co., and U.S. Pat. Nos. 3,929,678,2,658,072; 2,438,091; 2,528,378, which are incorporated herein byreference in their entirety.

Suitable nonionic surfactants for use in the present invention includethose described in McCutcheon's Detergents and Emulsifiers, NorthAmerican edition (2010), Allured Publishing Corp., and McCutcheon'sFunctional Materials, North American edition (2010). Suitable nonionicsurfactants for use in the Structure of the present invention include,but are not limited to, polyoxyethylenated alkyl phenols,polyoxyethylenated alcohols, polyoxyethylenated polyoxypropyleneglycols, glyceryl esters of alkanoic acids, polyglyceryl esters ofalkanoic acids, propylene glycol esters of alkanoic acids, sorbitolesters of alkanoic acids, polyoxyethylenated sorbitor esters of alkanoicacids, polyoxyethylene glycol esters of alkanoic acids,polyoxyethylenated alkanoic acids, alkanolamides, N-alkylpyrrolidones,alkyl glycosides, alkyl polyglucosides, alkylamine oxides, andpolyoxyethylenated silicones.

In another embodiment, the nonionic surfactant is selected from sorbitanesters and alkoxylated derivatives of sorbitan esters including sorbitanmonolaurate (SPAN® 20), sorbitan monopalmitate (SPAN® 40), sorbitanmonostearate (SPAN® 60), sorbitan tristearate (SPAN® 65), sorbitanmonooleate (SPAN® 80), sorbitan trioleate (SPAN® 85), sorbitanisostearate, polyoxyethylene (20) sorbitan monolaurate (Tween® 20),polyoxyethylene (20) sorbitan monopalmitate (Tween® 40), polyoxyethylene(20) sorbitan monostearate (Tween® 60), polyoxyethylene (20) sorbitanmonooleate (Tween® 80), polyoxyethylene (4) sorbitan monolaurate (Tween®21), polyoxyethylene (4) sorbitan monostearate (Tween® 61),polyoxyethylene (5) sorbitan monooleate (Tween® 81), all available fromUniqema, and combinations thereof.

Suitable copolymer surfactants include, but are not limited to, blockcopolymers of ethylene oxide and fatty alkyl residues, block copolymersof ethylene oxide and propylene oxide, hydrophobically modifiedpolyacrylates, hydrophobically modified celluloses, silicone polyethers,silicone copolyol esters, diquaternary polydimethylsiloxanes, andco-modified amino/polyether silicones.

The surfactant can be a combination of surfactants wherein one or moresurfactants from Group I, wherein Group I comprises anionic surfactants,and one or more surfactants from Group II, wherein Group II comprises asurfactant selected from the group consisting of amphoteric,zwitterionic and combinations thereof; wherein the ratio of Group I toGroup II surfactants is from about 90:10 to about 30:70.

C. Agglomerated Particle

The Dissolvable Solid Structure has from about 1 wt % to about 80 wt %preformed effervescent agglomerated particles, alternatively from about1 wt % to about 40 wt % preformed effervescent agglomerated particlesalternatively from about 5 to about 25 wt % of preformed effervescentagglomerated particles, alternatively from about 10 to about 15 wt % ofpreformed effervescent agglomerated particles. Effervescent salts arewidely used in the pharmaceutical and food industries. Suitableeffervescent salts (carbonate salts) include, but are not limited to,sodium bicarbonate and sodium carbonate. The effervescence, or ‘fizz’,provides a signal to the consumer that the product is effective. Themost common pairing of chemicals to produce the effervescent effect isSodium Bicarbonate and Citric Acid, which are solid materials. Thereaction equation is shown below:

3NaHCO₃+(C₆H₆O₇—H₂O)+4H₂O→Na₃C₆H₅O₇+3CO₂+8H₂O

The stoichiometry of the reaction indicates the weight ratio of 1:1.2citric acid:sodium bicarbonate balances this equation.

A preformed effervescent agglomerated particle (“agglomerated particle”)is an Agglomerated Particle that contains particles of both solidcarbonate salt and solid acid along with a binder that is prepared priorto incorporation into the fibrous web. A carbonate salt is any metalsalt of carbonic acid. A solid acid is any organic carboxylic acid thatis solid in room temperature; e.g. it has a melting point of higher than25° C. Preforming the effervescent agglomerated particle results in atconsumer noticeable benefit from the Dissolvable Solid Structure.Suitable solid acids include, but are not limited to, tartaric acid,citric acid, fumaric acid, adipic acid, malic acid, oxalic acid,sulfamic acid and combinations thereof. Suitable carbonate salts includebut are not limited to, sodium carbonate, calcium carbonate, magnesiumcarbonate, ammonium carbonate, potassium carbonate, sodium bicarbonate,potassium bicarbonate and calcium bicarbonate.

A binder is any material or substance that holds or draws othermaterials together to form a cohesive whole mechanically, chemically, oras an adhesive. The binder choice can have an effect on the foaming ofthe particle. Binders can include those that are nonionic to minimizethe interaction with the reactants, however, polymeric and ionic binderscan also be used. Suitable binders include, but are not limited to,Nonionic surfactants, nonionic polymers, Ethoxylated Alcohols, SorbitanDerivates, Polyethylene Glycols, Corn Syrup, Paraffin, waxes, FattyAlcohols, and mixtures thereof. Binders typically are included in theeffervescent agglomerated particle at a level of from about 0.05 weight% of the effervescent agglomerated particle to about 10 weight % of theeffervescent agglomerated particle, alternatively from about 1 weight %of the effervescent agglomerated particle to about 5 weight % of theeffervescent agglomerated particle. Binders typically are included atfrom about 0.05 to about to about 5 weight % of the Dissolvable SolidStructure.

The agglomerated particles can be evenly distributed throughout thefiber matrix. The agglomerated particles may be distributed evenly onone layer or throughout multiple layers. For example one method ishaving it evenly distributed on all layers of the web. Alternatively,the agglomerated particle could be distributed through a middle layer,alternatively the agglomerated particle could be distributed only on anexternal layer outwardly facing layer.

The effervescent reaction is an acid/base neutralization reaction.During the reaction CO2 evolves, giving the characteristic effervescencedesired in this product. The reaction will take place in the presence ofmoisture in the air, and auto-catalytically continue, at wateractivities above about 0.6 aW. Adding humectant to the effervescentagglomerated particle allows water from the air or from reactingmaterials to be absorbed, preventing or delaying the reaction. Thisimproves process ability as well as shelf stability. The data belowshows that increasing levels of humectant, in these examples PotassiumAcetate, results in better stability of the effervescent agglomeratedparticles, as measured in mass loss due to CO2 release and flowability.Suitable humectants include Salts, sugars, acids, glycols, inorganicsand combinations thereof. Suitable humectants can be selected fromPEG400, PEG 600, Sorbitol, Potassium Carbonate, Sodium Chloride,Potassium Acetate, PEG 4000, zeolite, Corn syrup, Glycerol, Fructose,Sucrose, citric acid, tartaric acid, malic acid, lactic acid, MagnesiumChloride, and combinations thereof. Suitable humectant ranges are fromabout 0.1 to about 15 weight % of the effervescent agglomeratedparticle, alternatively from about 1 to about 7 weight % of theeffervescent agglomerated particle. Suitable humectant ranges includefrom about 0.5 to about 10 weight % of the Dissolvable Solid Structure,alternatively from about 1 to about 7 weight % of the Dissolvable SolidStructure.

Flow aides can be included at low levels to help make the AgglomeratedParticle flow better, non-limiting examples include Zeolite A,precipitated silica, precipitated silicates, fly ash, talc, starch,clays, metallic stearates, phosphates, amides, polysaccharides, sugars,and combinations thereof. Particularly suitable materials includeZeolite A, silica, sugars and mixtures thereof.

The effervescent agglomerated particle is based on the citricacid/sodium bicarbonate reaction shown above. There is a binder used tohold the particles together, a humectant added to provide stability withrespect to moisture, and in some instances, a flow aide.

Method of Making Agglomerated Particles

Citric acid, sodium bicarbonate and humectant are mixed in a convectiveor tumbling solids mixer including paddle mixers or v-blenders forapproximately 5 minutes. Binder is added and mixed for an additional 5min, or longer for larger particles or shorter for smaller particles.The flow aid is added after Agglomerated Particle has reached targetsize. Mixing continues for approximately another minute. AgglomeratedParticle is transferred into storage vessel until ready for use.

Particle size is controlled by the initial raw material particle size,binder selection, and the time of mixing after binder addition inagglomeration process. In one example, large Citric Acid, 400-500 μm, ischosen as a seed particle, the binder is nonionic binder to stick tosmaller Sodium Bicarbonate particles, 50-100 μm, to the seed, and thencoating the entire particle with Zeolite, less than about 10 μm, as aflow aid. Size is controlled primarily by citric acid size selection.

Suitable size is above 300 microns for the effervescent AgglomeratedParticles for the typical process to have acceptable inclusion into theDissolvable Solid Structure.

Suitable effervescent particles include those having a particle size offrom about 100 microns to about 2000 microns. Suitable effervescentparticles include those having a particle size of less than 2000microns, alternatively less than 1000 microns, alternatively less than800 micron. Large particles can have less consumer acceptance among someconsumers because they are perceived as a gritty feel on their handsduring dissolution. However, other consumers prefer larger particlespreferably greater than 1000 microns, more preferably greater than 2000microns so that as they feel them dissolve they know it is time to applythe product to hair. Suitable large particles can have a particle sizeof from about 1000 to about 5000 microns.

TABLE 5 Agglomerated Agglomerated Agglomerated Particle ParticleParticle Ingredients Example Example Example Citric acid 41.7% 41.7%41.7% Sodium bicarbonate 50.0% 50.0% 50.0% Polysorbate- 80¹ 1.0% 1.0%1.0% Sodium Aluminum 7.3% 7.3% 7.3% Silicate² Agglomerated 1000 micron600 micron 300 micron Particle size³ ¹Tween-80 supplied by Croda²Zeolite A supplied by Sasol ³Pass through standard screens ofdesignated sizes.

Optional Ingredients

The Structure (dried) optionally comprises from about 1 wt % to about 25wt % plasticizer, in one embodiment from about 3 wt % to about 20 wt %plasticizer, in one embodiment from about 5 wt % to about 15 wt %plasticizer.

When present in the Structures, non-limiting examples of suitableplasticizing agents include polyols, copolyols, polycarboxylic acids,polyesters and dimethicone copolyols.

Examples of useful polyols include, but are not limited to, glycerin,diglycerin, propylene glycol, ethylene glycol, butylene glycol,pentylene glycol, cyclohexane dimethanol, hexane diol, polyethyleneglycol (200-600), sugar alcohols such as sorbitol, manitol, lactitol andother mono- and polyhydric low molecular weight alcohols (e.g., C₂-C₈alcohols); mono di- and oligosaccharides such as fructose, glucose,sucrose, maltose, lactose, and high fructose corn syrup solids andascorbic acid.

Examples of polycarboxylic acids include, but are not limited to citricacid, maleic acid, succinic acid, polyacrylic acid, and polymaleic acid.

Examples of suitable polyesters include, but are not limited to,glycerol triacetate, acetylated-monoglyceride, diethyl phthalate,triethyl citrate, tributyl citrate, acetyl triethyl citrate, acetyltributyl citrate.

Examples of suitable dimethicone copolyols include, but are not limitedto, PEG-12 dimethicone, PEG/PPG-18/18 dimethicone, and PPG-12dimethicone.

Other suitable plasticizers include, but are not limited to, alkyl andallyl phthalates; napthalates; lactates (e.g., sodium, ammonium andpotassium salts); sorbeth-30; urea; lactic acid; sodium pyrrolidonecarboxylic acid (PCA); sodium hyraluronate or hyaluronic acid; solublecollagen; modified protein; monosodium L-glutamate; alpha & betahydroxyl acids such as glycolic acid, lactic acid, citric acid, maleicacid and salicylic acid; glyceryl polymethacrylate; polymericplasticizers such as polyquaterniums; proteins and amino acids such asglutamic acid, aspartic acid, and lysine; hydrogen starch hydrolysates;other low molecular weight esters (e.g., esters of C₂-C₁₀ alcohols andacids); and any other water soluble plasticizer known to one skilled inthe art of the foods and plastics industries; and mixtures thereof.

EP 0283165 B1 discloses suitable plasticizers, including glycerolderivatives such as propoxylated glycerol.

The Structure may comprise other optional ingredients that are known foruse or otherwise useful in compositions, provided that such optionalmaterials are compatible with the selected essential materials describedherein, or do not otherwise unduly impair product performance.

Such optional ingredients are most typically those materials approvedfor use in cosmetics and that are described in reference books such asthe CTFA Cosmetic Ingredient Handbook, Second Edition, The Cosmetic,Toiletries, and Fragrance Association, Inc. 1992.

Emulsifiers suitable as an optional ingredient herein include mono- anddi-glycerides, fatty alcohols, polyglycerol esters, propylene glycolesters, sorbitan esters and other emulsifiers known or otherwisecommonly used to stabilized air interfaces, as for example those usedduring preparation of aerated foodstuffs such as cakes and other bakedgoods and confectionary products, or the stabilization of cosmetics suchas hair mousses.

Further non-limiting examples of such optional ingredients includepreservatives, perfumes or fragrances, coloring agents or dyes,conditioning agents, hair bleaching agents, thickeners, moisturizers,emollients, pharmaceutical actives, vitamins or nutrients, sunscreens,deodorants, sensates, plant extracts, nutrients, astringents, cosmeticparticles, absorbent particles, adhesive particles, hair fixatives,fibers, reactive agents, skin lightening agents, skin tanning agents,anti-dandruff agents (example zinc pyrithione and selenium sulfideetc.), perfumes, exfoliating agents, acids, bases, humectants, enzymes,suspending agents, pH modifiers, hair colorants, hair perming agents,pigment particles, anti-acne agents, anti-microbial agents, sunscreens,tanning agents, exfoliation particles, hair growth or restorer agents,insect repellents, shaving lotion agents, co-solvents or otheradditional solvents, and similar other materials.

Suitable conditioning agents include high melting point fatty compounds,silicone conditioning agents and cationic conditioning polymers.Suitable materials are discussed in US 2008/0019935, US 2008/0242584 andUS 2006/0217288.

Non-limiting examples of product type embodiments for use by theStructure include hand cleansing Structures, hair shampoo or other hairtreatment Structures, body cleansing Structures, shaving preparationStructures, personal care Structures containing pharmaceutical or otherskin care active, moisturizing Structures, sunscreen Structures, chronicskin benefit agent Structures (e.g., vitamin-containing Structures,alpha-hydroxy acid-containing Structures, etc.), deodorizing Structures,fragrance-containing Structures, and so forth.

The Structures are dissolvable, porous solid compositions wherein theporosity allows for liquid (e.g., water) flow during use such that thesolid composition readily dissolves to provide a desired consumerexperience. The porous nature of the Structure can be achieved in avariety of ways including, for example, forming an open celled foam orforming a fibrous structure.

For fibrous Structures, the Structure comprises a significant number ofdissolvable fibers with an average diameter less than about 150 micron,alternatively less than about 100 micron, alternatively less than about20 micron, alternatively less than about 10 micron, and alternativelyless than about 1 micron with a relative standard deviation of less than100%, alternatively less than 80%, alternatively less than 60%,alternatively less than 50%, such as in the range of 10% to 50%, forexample. As set forth herein, the significant number means at least 10%of all the dissolvable fibers, alternatively at least 25% of all thedissolvable fibers, alternatively at least 50% of all the dissolvablefibers, alternatively at least 75% of all the dissolvable fibers. Thesignificant number may be at least 99% of all the dissolvable fibers.Alternatively, from about 50% to about 100% of all the dissolvablefibers may have an average diameter less than about 20 micron. Thedissolvable fibers produced by the method of the present disclosure havea significant number of dissolvable fibers with an average diameter lessthan about 1 micron, or sub-micron fibers. In an embodiment, DissolvableSolid Structure may have from about 25% to about 100% of all thedissolvable fibers with an average diameter less than about 1 micron,alternatively from about 35% to about 100% of all the dissolvable fiberswith an average diameter less than about 1 micron, alternatively fromabout 50% to about 100% of all the dissolvable fibers with an averagediameter less than about 1 micron, and alternatively from about 75% toabout 100% of all the dissolvable fibers with an average diameter lessthan about 1 micron.

The percent porosity of the dissolvable solid Structure is at leastabout 25%, alternatively at embodiment at least about 50%, alternativelyat least about 60%, alternatively at least about 70% and alternativelyat least about 80%. The porosity of the dissolvable solid Structure isnot more than about 99%, alternatively not more than about 98%,alternatively not more than about 95%, and alternatively not more thanabout 90%. Porosity of a Structure is determined according to theprocedure set forth in the definition of “porosity” above.

A range of effective sizes of pores can be accommodated. The pore sizedistribution through the Structure cross-section may be symmetric orasymmetric.

The Structure can be flexible and have a distance to maximum force valueof from about 6 mm to about 30 mm. The distance to maximum force valuefrom about 7 mm to about 25 mm, alternatively from about 8 mm to about20 mm, and alternatively from about 9 mm to about 15 mm.

The Structure can be a flat, flexible Structure in the form of a pad, astrip, or tape and having a thickness of from about 0.5 mm to about 10mm, alternatively from about 1 mm to about 9 mm, alternatively fromabout 2 mm to about 8 mm, and alternatively from about 3 mm to about 7mm as measured by the below methodology. The Structure can be a sheethaving a thickness from about 5 mm to about 6.5 mm. Alternatively two ormore sheets are combined to form a Structure with a thickness of about 5mm to about 10 mm.

Methods of Manufacture—Fibrous Structures Method for Making FibrousElements

The fibrous elements of the present invention may be made by anysuitable process. A non-limiting example of a suitable process formaking the fibrous elements is described below.

The fibrous elements of the present invention may be made as follows.Fibrous elements may be formed by means of a small-scale apparatus. Apressurized tank, suitable for batch operation is filled with a suitablefilament-forming composition according to the present invention. A pumpsuch as a Zenith®, type PEP II, having a capacity of 5.0 cubiccentimeters per revolution (cc/rev), manufactured by Parker HannifinCorporation, Zenith Pumps division, of Sanford, N.C., USA may be used tofacilitate transport of the filament-forming composition via pipes to aspinning die. The flow of the filament-forming composition from thepressurized tank to the spinning die may be controlled by adjusting thenumber of revolutions per minute (rpm) of the pump. Pipes are used toconnect the pressurized tank, the pump, and the spinning die.

The spinning die can have several rows of circular extrusion nozzles(fibrous element-forming holes) spaced from one another at a pitch P ofabout 1.524 millimeters (about 0.060 inches). The nozzles haveindividual inner diameters of about 0.305 millimeters (about 0.012inches) and individual outside diameters of about 0.813 millimeters(about 0.032 inches). Each individual nozzle is encircled by an annularand divergently flared orifice (concentric attenuation fluid hole tosupply attenuation air to each individual melt capillary. Thefilament-forming composition extruded through the nozzles is surroundedand attenuated by generally cylindrical, humidified air streams suppliedthrough the orifices.

A method for making a fibrous element 10 comprises the steps of:

a. providing a filament-forming composition comprising one or morefilament-forming materials, and optionally one or more active agents;and

b. spinning the filament-forming composition, such as via a spinningdie, into one or more fibrous elements, such as filaments 10, comprisingthe one or more filament-forming materials and optionally, the one ormore active agents. The one or more active agents may be releasable fromthe fibrous element when exposed to conditions of intended use. Thetotal level of the one or more filament-forming materials present in thefibrous element, for example filament 10, when active agents are presenttherein, may be less than 80% and/or less than 70% and/or less than 65%and/or 50% or less by weight on a dry fibrous element basis and/or dryfibrous structure basis and the total level of the one or more activeagents, when present in the fibrous element may be greater than 20%and/or greater than 35% and/or 50% or greater 65% or greater and/or 80%or greater by weight on a dry fibrous element basis and/or dry fibrousstructure basis.

The spinning die may comprise a plurality of fibrous element-formingholes that include a melt capillary encircled by a concentricattenuation fluid hole through which a fluid, such as air, passes tofacilitate attenuation of the filament-forming composition into afibrous element, for example a filament 10 as it exits the fibrouselement-forming hole.

Attenuation air can be provided by heating compressed air from a sourceby an electrical-resistance heater, for example, a heater manufacturedby Chromalox, Division of Emerson Electric, of Pittsburgh, Pa., USA. Anappropriate quantity of steam was added to saturate or nearly saturatethe heated air at the conditions in the electrically heated,thermostatically controlled delivery pipe. Condensate is removed in anelectrically heated, thermostatically controlled, separator.

The embryonic fibrous elements are dried by a drying air stream having atemperature from about 149° C. (about 300° F.) to about 315° C. (about600° F.) by an electrical resistance heater (not shown) supplied throughdrying nozzles and discharged at an angle of about 90° relative to thegeneral orientation of the embryonic fibrous elements being extruded.The dried embryonic fibrous elements are collected on a collectiondevice, such as, for example, a movable foraminous belt or patternedcollection belt. The addition of a vacuum source directly under theformation zone may be used to aid collection of the fibers.

In one example, during the spinning step, any volatile solvent, such aswater, present in the filament-forming composition is removed, such asby drying, as the fibrous element 10 is formed. In one example, greaterthan 30% and/or greater than 40% and/or greater than 60% of the weightof the filament-forming composition's volatile solvent, such as water,is removed during the spinning step, such as by drying the fibrouselement being produced.

The filament-forming composition may comprise any suitable total levelof filament-forming materials and any suitable level of active agents solong as the fibrous element produced from the filament-formingcomposition comprises a total level of filament-forming materials in thefibrous element of from about 5% to 50% or less by weight on a dryfibrous element basis and/or dry particle basis and/or dry fibrousstructure basis and a total level of active agents in the fibrouselement of from 50% to about 95% by weight on a dry fibrous elementbasis and/or dry particle basis and/or dry fibrous structure basis.

In one example, the filament-forming composition may comprise anysuitable total level of filament-forming materials and any suitablelevel of active agents so long as the fibrous element produced from thefilament-forming composition comprises a total level of filament-formingmaterials in the fibrous element and/or particle of from about 5% to 50%or less by weight on a dry fibrous element basis and/or dry particlebasis and/or dry fibrous structure basis and a total level of activeagents in the fibrous element and/or particle of from 50% to about 95%by weight on a dry fibrous element basis and/or dry particle basisand/or dry fibrous structure basis, wherein the weight ratio offilament-forming material to total level of active agents is 1 or less.

In one example, the filament-forming composition comprises from about 1%and/or from about 5% and/or from about 10% to about 50% and/or to about40% and/or to about 30% and/or to about 20% by weight of thefilament-forming composition of filament-forming materials; from about1% and/or from about 5% and/or from about 10% to about 50% and/or toabout 40% and/or to about 30% and/or to about 20% by weight of thefilament-forming composition of active agents; and from about 20% and/orfrom about 25% and/or from about 30% and/or from about 40% and/or toabout 80% and/or to about 70% and/or to about 60% and/or to about 50% byweight of the filament-forming composition of a volatile solvent, suchas water. The filament-forming composition may comprise minor amounts ofother active agents, such as less than 10% and/or less than 5% and/orless than 3% and/or less than 1% by weight of the filament-formingcomposition of plasticizers, pH adjusting agents, and other activeagents.

The filament-forming composition is spun into one or more fibrouselements and/or particles by any suitable spinning process, such asmeltblowing, spunbonding, electro-spinning, and/or rotary spinning Inone example, the filament-forming composition is spun into a pluralityof fibrous elements and/or particles by meltblowing. For example, thefilament-forming composition may be pumped from a tank to a meltblownspinnerette. Upon exiting one or more of the filament-forming holes inthe spinnerette, the filament-forming composition is attenuated with airto create one or more fibrous elements and/or particles. The fibrouselements and/or particles may then be dried to remove any remainingsolvent used for spinning, such as the water.

The fibrous elements and/or particles of the present invention may becollected on a belt, such as a patterned belt to form a fibrousstructure comprising the fibrous elements and/or particles.

Method for Making Fibrous Structures

A fibrous structure, for example a fibrous structure layer or ply of thepresent invention may be made by spinning a filament-forming compositionfrom a spinning die, to form a plurality of fibrous elements, such asfilaments 10. The fibrous elements may be spun via suitable spinningprocess operations, such as meltblowing, spunbonding, electro-spinning,and/or rotary spinning.

The dry embryonic fibrous elements, for example filaments may becollected on a molding member as described above. The construction ofthe molding member may provide areas that are air-permeable due to theinherent construction. The filaments that are used to construct themolding member will be non-permeable while the void areas between thefilaments will be permeable. Additionally a pattern may be applied tothe molding member to provide additional non-permeable areas which maybe continuous, discontinuous, or semi-continuous in nature. A vacuumused at the point of lay down is used to help deflect fibers into thepresented pattern.

In addition to the techniques described herein in forming regions withinthe fibrous structures having a different properties (e.g., averagedensities), other techniques can also be applied to provide suitableresults. One such example includes embossing techniques to form suchregions. Suitable embossing techniques are described in U.S. PatentApplication Publication Nos. 2010/0297377, 2010/0295213, 2010/0295206,2010/0028621, and 2006/0278355.

In one example, in a multi-ply article, one or more fibrous structureplies may be formed and/or deposited directly upon an existing ply offibrous structure to form a multi-ply fibrous structure. The two or moreexisting fibrous structure plies may be combined, for example viathermal bonding, gluing, embossing, aperturing, rotary knife aperturing,die cutting, die punching, needlepunching, knurling, pneumatic forming,hydraulic forming, laser cutting, tufting, and/or other mechanicalcombining process, with one or more other existing fibrous structureplies to form the multi-ply article of the present invention.

Pre-formed dissolvable fibrous web (comprised of dissolvable fibers and,optionally, agglomerate particles), having approximately ⅓ the totaldesired basis weight of the finished article, can be arranged in a faceto face relationship with post-add minor ingredients disposed betweenlayers, and laminated with a solid state formation process. Theresulting laminate is cut into the finished article shape via diecutting.

Lamination and Formation of Apertures via Solid State Formation

The 3-layer web stack with minors disposed between layers can be passedtogether through a solid state formation process (see Rotary KnifeAperturing Apparatus below), forming roughly conical apertures in thearticle and causing inter-layer fiber interactions which result in amechanically lamination article. Lamination aids (e.g. web plasticizingagents, adhesive fluids, etc.) may be additionally used to aid in securelamination of layers.

Rotary Knife Aperturing Apparatus

Suitable solid state description in disclosed in U.S. Pat. No.8,679,391. Also, suitable dissolvable web aperturing description isdisclosed in US 2016/0101026A1.

The nip comprises (2) intermeshed 100 pitch toothed rolls The teeth onthe toothed rolls have a pyramidal shape tip with six sides that taperfrom the base section of the tooth to a sharp point at the tip. The basesection of the tooth has vertical leading and trailing edges and isjoined to the pyramidal shape tip and the surface of the toothed roller.The teeth are oriented so the long direction runs in the MD.

The teeth are arranged in a staggered pattern, with a CD pitch P of0.100 inch (2.5 mm) and a uniform tip to tip spacing in the MD of 0.223inch (5.7 mm). The overall tooth height TH (including pyramidal andvertical base sections) is 0.270 inch (6.9 mm), the side wall angle onthe long side of the tooth is 6.8 degrees and the side wall angle of theleading and trailing edges of the teeth in the pyramidal tip section is25 degrees.

The opposing toothed rolls are aligned such that the corresponding MDrows of teeth are in different planes and said planes are approximatelyequidistant from neighboring planes of the opposing roller; that is,such that the clearances on either side of the teeth are about equal.The degree of interference between the virtual cylinders described bythe tips of the pins is described as the Depth of Engagement.

As web passes through the nip formed between the opposing rollers, theteeth from each roller engage with and penetrate the web to a depthdetermined largely by the depth of engagement between the rollers andthe nominal thickness of the web. The opposing toothed rolls are alignedsuch that the corresponding MD rows of teeth are in different planes andsaid planes are approximately equidistant from neighboring planes of theopposing roller; that is, such that the clearances on either side of theteeth are about equal.

The Optional Preparing of the Surface Resident Coating Comprising theActive Agent

The preparation of the surface resident coating comprising the activeagent may include any suitable mechanical, chemical, or otherwise meansto produce a composition comprising the active agent(s) including anyoptional materials as described herein, or a coating from a fluid.

Optionally, the surface resident coating may comprise a water releasablematrix complex comprising active agent(s). In one embodiment, the waterreleasable matrix complexes comprising active agent(s) are prepared byspray drying wherein the active agent(s) is dispersed or emulsifiedwithin an aqueous composition comprising the dissolved matrix materialunder high shear (with optional emulsifying agents) and spray dried intoa fine powder. The optional emulsifying agents can include gum arabic,specially modified starches, or other tensides as taught in the spraydrying art (See Flavor Encapsulation, edited by Sara J. Risch and GaryA. Reineccius, pages 9, 45-54 (1988), which is incorporated herein byreference). Other known methods of manufacturing the water releasablematrix complexes comprising active agent(s) may include but are notlimited to, fluid bed agglomeration, extrusion, cooling/crystallizationmethods and the use of phase transfer catalysts to promote interfacialpolymerization. Alternatively, the active agent(s) can be adsorbed orabsorbed into or combined with a water releasable matrix material thathas been previously produced via a variety of mechanical mixing means(spray drying, paddle mixers, grinding, milling etc.). In oneembodiment, the water releasable matrix material in either pellet orgranular or other solid-based form (and comprising any minor impuritiesas supplied by the supplier including residual solvents andplasticizers) may be ground or milled into a fine powder in the presenceof the active agent(s) via a variety of mechanical means, for instancein a grinder or hammer mill.

Where the Dissolvable Solid Structure has a particulate coating, theparticle size is known to have a direct effect on the potential reactivesurface area of the active agents and thereby has a substantial effecton how fast the active agent delivers the intended beneficial effectupon dilution with water. In this sense, the active agents with smallerparticle sizes tend to give a faster and shorter lived effect, whereasthe active agents with larger particle sizes tend to give a slower andlonger lived effect. In one embodiment the surface resident coatings mayhave a particle size from about 1 μm to about 200 μm, in anotherembodiment from about 2 μm to about 100 μm, and in yet anotherembodiment from about 3 μm to about 50 μm.

In some embodiments, it is helpful to include inert fillers within thegrinding process, for instance aluminum starch octenylsuccinate underthe trade name DRY-FLO® PC and available from Akzo Nobel, at a levelsufficient to improve the flow properties of the powder and to mitigateinter-particle sticking or agglomeration during powder production orhandling. Other optional excipients or cosmetic actives, as describedherein, can be incorporated during or after the powder preparationprocess, e.g., grinding, milling, blending, spray drying, etc. Theresulting powder may also be blended with other inert powders, either ofinert materials or other powder-active complexes, and including waterabsorbing powders as described herein.

In one embodiment, the active agents may be surface coated withnon-hygroscopic solvents, anhydrous oils, and/or waxes as definedherein. This may include the steps of: (i) coating the water sensitivepowder with the non-hydroscopic solvents, anhydrous oils, and/or waxes;(ii) reduction of the particle size of the active agent particulates,prior to, during, or after a coating is applied, by known mechanicalmeans to a predetermined size or selected distribution of sizes; and(iii) blending the resulting coated particulates with other optionalingredients in particulate form. Alternatively, the coating of thenon-hydroscopic solvents, anhydrous oils and/or waxes may besimultaneously applied to the other optional ingredients, in addition tothe active agents, of the surface resident coating composition and withsubsequent particle size reduction as per the procedure described above.

Where the coating is applied to the Structure as a fluid (such as by asa spray, a gel, or a cream coating), the fluid can be prepared prior toapplication onto the Structure or the fluid ingredients can beseparately applied onto the Structure such as by two or more spray feedsteams spraying separate components of the fluid onto the Structure.

Post-add minor ingredients can be applied to the surface of one or moreweb layers in the nascent article, typically an interior surface.Individual minor ingredients may be applied together to a singleselected surface or to separate surfaces. Minor ingredients may beapplied to interior or exterior surfaces. In the present examples,minors were applied to the same interior surface, namely to one side ofthe middle of three layers.

Post-add ingredients in the present examples include fragrance andamodimethicone, both fluid at room temperature. Additional minoringredients could include alternative conditioning agents,co-surfactants, encapsulated fragrance vehicles, rheology modifiers,etc. Minor ingredients could include fluids, particulates, pastes, orcombinations.

In the present examples, fragrance is applied by atomizing through aspray nozzle (example Nordson EFD spray nozzle) and directing theresulting droplets of perfume to the target web surface, essentiallyuniformly over the surface.

In the present examples, amodimethicone is applied by expressing thefluid through an extrusion nozzle (example ITW-Dynatec UFD hot melt gluenozzle), comprising a series of orifices, approximately 500 microns indiameter and spaced at 2.5 mm, resulting in stripes of fluid extendingthe length of the target web surface.

Alternate fluid dispensing technologies, application patterns, andcharacteristic dimensions are contemplated.

Methods of Use

The compositions described herein may be used for cleaning and/ortreating hair, hair follicles, skin, teeth, and the oral cavity. Themethod for treating these consumer structure may comprise the steps of:a) applying an effective amount of the Structure to the hand, b) wettingthe Structure with water to dissolve the solid, c) applying thedissolved material to the target consumer substrate such as to clean ortreat it, and d) rinsing the diluted treatment composition from theconsumer substrate. These steps can be repeated as many times as desiredto achieve the desired cleansing and or treatment benefit.

According to yet another embodiment, a method is provided for providinga benefit to hair, hair follicles, skin, teeth, and/or the oral cavity,comprising the step of applying a composition according to the firstembodiment to these target consumer substrates in need of regulating.

Described herein is a method for regulating the condition of hair, hairfollicles, skin, teeth, the oral cavity, comprising the step of applyingone or more compositions described herein to these target consumersubstrates in need of regulation.

The amount of the composition applied, the frequency of application andthe period of use will vary widely depending upon the purpose ofapplication, the level of components of a given composition and thelevel of regulation desired. For example, when the composition isapplied for whole body or hair treatment, effective amounts generallyrange from about 0.5 grams to about 10 grams, in one embodiment fromabout 1.0 grams to about 5 grams, and in another embodiment from about1.5 grams to about 3 grams.

VI. Product Types and Articles of Commerce

Non-limiting examples of product embodiments that utilize the Structuresinclude hand cleansing substrates, teeth cleaning or treatingsubstrates, oral cavity substrates, hair shampoo or other hair treatmentsubstrates, body cleansing substrates, shaving preparation substrates,personal care substrates containing pharmaceutical or other skin careactive, moisturizing substrates, sunscreen substrates, chronic skinbenefit agent substrates (e.g., vitamin-containing substrates,alpha-hydroxy acid-containing substrates, etc.), deodorizing substrates,fragrance-containing substrates, and so forth.

Described herein is an article of commerce comprising one or moreStructures described herein, and a communication directing a consumer todissolve the Structure and apply the dissolved mixture to hair, hairfollicles, skin, teeth, the oral cavity, to achieve a benefit to thetarget consumer substrate, a rapidly lathering foam, a rapidly rinsingfoam, a clean rinsing foam, and combinations thereof. The communicationmay be printed material attached directly or indirectly to packagingthat contains the Structure or on the Structure itself. Alternatively,the communication may be an electronic or a broadcast message that isassociated with the article of manufacture. Alternatively, thecommunication may describe at least one possible use, capability,distinguishing feature and/or property of the article of manufacture.

Test Methods Basis Weight Measurement

In general, basis weight of a material or article (including thedissolvable solid structure) is measured by first cutting the sample toa known area, using a die cutter or equivalent, then measuring &recording the weight of the sample on a top-loading balance with aminimum resolution of 0.01 g, then finally by calculating the basisweight as follows: Basis Weight (g/m2)=weight of basis weight pad (g)

${{Basis}{Weight}\left( \frac{g}{m^{2}} \right)} = \frac{{Weight}{of}{pad}(g) \times 10,000\frac{{cm}^{2}}{m^{2}}}{{area}{of}{pad}\left( {cm}^{2} \right)}$

Preferred pad sample sizes for basis weight determination are >10 cm2and should be cut with a precision die cutter having the desiredgeometry. If the article to be measured is smaller than 10 cm2, asmaller sampling area can be used for basis weight determination withthe appropriate changes to calculation.

In the present examples, basis weight was calculated based on the fullarticle having a known area of 17.28 cm2. Thus, the basis weightcalculation becomes:

${{Basis}{Weight}\left( \frac{g}{m^{2}} \right)} = \frac{{Weight}{of}{pad}(g) \times 10,000\frac{{cm}^{2}}{m^{2}}}{17.28{cm}^{2}}$

Thickness (Caliper) Measurement

The present examples were measured using the Check-Line J-40-V DigitalMaterial Thickness Gauge from Electromatic Equipment Co. (Cedarhurst,N.Y.).

The sample (such as the dissolvable solid structure) is placed between atop and bottom plate of the instrument which has a top plate designed toapply a pressure of 0.5 kPa over a 25 cm2 area. The distance between theplates, to the nearest 0.01 mm, at the time of measurement is recordedas the thickness of the sample. The time of measurement is determined asthe time at which the thickness in mm stabilizes or 5 seconds, whicheveroccurs first.

Equivalent methods are described in detail in compendial method ISO9073-2, Determination of thickness for nonwovens, or equivalent.

Bulk Density (Density) Determination

Bulk Density is determined by calculation given a Thickness and BasisWeight of the sample (the solid dissolvable structure) (using methods asdescribed above) according to the following:

${{Bulk}{Density}\left( \frac{g}{{cm}^{3}} \right)} = \frac{{Basis}{Weight}{of}{the}{pad}\left( \frac{g}{m^{2}} \right)}{{Thickness}{of}{the}{pad}({mm}) \times 0.1\frac{cm}{mm} \times 10,000\frac{{cm}^{2}}{m^{2}}}$

Surfactant Density Determination

Surfactant density is determined by calculation, given a Bulk Density ofthe material and a surfactant activity (fraction of the article that issurfactant).

${{Surfactant}{Density}\left( \frac{g}{{cm}^{3}} \right)} = {{Bulk}{Density}\left( \frac{g}{{cm}^{3}} \right) \times {Surfactant}{Activity}\left( \frac{g}{g} \right)}$

Method of Measuring the footprint of a dissolvable solid structure (orarticle)

The footprint of the dissolvable structure/article can be measured bymeasuring the dimensions of its base so that the base area (that is, thefootprint) can be calculated. For example, in the case in which the baseof the article is a parallelogram having right angles, the length of theunequal sides of the base (A and B) are measured by a ruler and the areaof the base (footprint) is calculated as the product A×B. In the case inwhich the base of the article is a square, the length of a side (C) ismeasured by a ruler and the area of the base (footprint) is calculatedas the square C2. Other examples of shapes can include circle, oval,etc.

Distance to Maximum Force Method

Measured via a Rupture Method on a Texture Analyzer using a TA-57Rcylindrical probe with Texture Exponent 32 Software. The Structureshould have a thickness of between 4 to 7 mm and cut in a circle with adiameter of at least 7 mm for this method; or carefully cut or stackedto be within this overall thickness and diameter range. The porous solidsample is carefully mounted on top of the cylinder with four screwsmounted on top with the top lid affixed in place on top of the sample.There is a hole in the center of the cylinder and its lid which allowsthe probe to pass through and stretch the sample. The sample is measuredwith a pre-test speed of 1 mm per second, a test speed of 2 mm persecond and a post test speed of 3 mm per second over a total distance of30 mm. The distance to maximum force is recorded.

Hand Dissolution Test Method Materials Needed:

Articles to be tested: 3-5 articles (finished product samples)(dissolvable solid structures) are tested so that an average of thenumber of strokes for each if the individual article samples iscalculated and recorded as the Average Hand Dissolution value for thearticle. For this method, the entire consumer saleable or consumer usearticle is tested. If the entire consumer saleable or consumer usearticle has a footprint greater than 50 cm², then first cut the articleto have a footprint of 50 cm².

Nitrile Gloves

10 cc syringe

Plastic Weigh boat (˜3 in×3 in)

100 mL Glass beaker

Water (City of Cincinnati Water or equivalent having the followingproperties: Total Hardness=155 mg/L as CaCO2; Calcium content=33.2 mg/L;Magnesium content=17.5 mg/L;

Phosphate content=0.0462 mg/L)Water used is 7 gpg hardness and 40° C. +/−5° C.

Protocol:

-   -   Add 300-500 ml of water to glass beaker.    -   Heat water in beaker until water is at a temperature of 40°        C.+/−5° C.    -   Transfer 10 mL of the water from the beaker into the weigh boat        via the syringe.    -   Within 10 seconds of transferring the water to the weigh boat,        place article sample in palm of gloved hand (hand in cupped        position in non-dominant hand to hold article sample).    -   Using dominant hand, add water quickly from the weigh boat to        the article sample and allow to immediately wet for a period of        5-10 seconds.    -   Rub with opposite dominant hand (also gloved) in 2 rapid        circular strokes.    -   Visually examine the article sample in hand after the 2 strokes.        If article sample is completely dissolved, record number of        strokes=2 Dissolution Strokes. If not completely dissolved, rub        remaining article sample for 2 more circular strokes (4 total)        and observe degree of dissolution. If article sample contains no        solid pieces after the 2 additional strokes, record number of        strokes=4 Dissolution Strokes. If after the 4 strokes total, the        article sample still contains solid pieces of un-dissolved        article sample, continue rubbing remaining article sample in        additional 2 circular strokes and check if there are any        remaining solid pieces of article sample after each additional 2        strokes until article sample is completely dissolved or until        reaching a total of 30 strokes, whichever comes first. Record        the total number of strokes. Record 30 Dissolution Strokes even        if solid article sample pieces remain after the maximum of 30        strokes.    -   Repeat this process for each of the additional 4 article        samples.    -   Calculate the arithmetic mean of the recorded values of        Dissolution Strokes for the 5 individual article samples and        record as the Average Hand Dissolution Value for the article.        The Average Hand Dissolution Value is reported to the nearest        single Dissolution Stroke unit.

Lather Profile: Lather Volume

The Structure provides a lather profile as described hereafter. Thelather volume assessment is performed on 15 g/10 inch flat Orientalvirgin hair switches that have been treated with 0.098 g of artificialliquid sebum [10-22% olive oil, 18-20% coconut oil, 18-20% oleic acid,5-9% lanolin, 5-9% squalene, 3-6% palmitic acid, 3-6% paraffin oil, 3-6%dodecane, 1-4% stearic acid, 1-4% cholesterol, 1-4% coconut fatty acid,18-20% choleth-24]. The hair switch is rinsed with 9-11 grain, 100° F.water at 1.5 gallons/min for 20 seconds with a shower nozzle. Fortesting the liquid control products, 0.75 cm³ of liquid product areapplied to the center of the switch, the lower portion of hair on theswitch is then rubbed over the product on the hair 10 times in acircular motion, followed by 40 strokes back and forth (a total of 80strokes). Lather speed is recorded as the number of strokes when thefirst lather is obviously generated during the 80 strokes. Lather fromoperator's gloves is transferred to a graduated cylinder with a 3.5 cminside diameter and with total capacities of either 70 mL, 110 ml, or140 ml depending on the total amount of lather generated (heightmodification of standard sized graduated cylinders via a glass shop).Lather from hair is gathered using one downward stroke on the switchwith a tight grip and is also placed into the cylinder. Total lathervolume is recorded in milliliters. Three runs per test sample areperformed and the mean of the three values is calculated. When testingthe Structure, 0.20+/−0.01 grams of product are weighed with the aid ofscissors if needed and applied to the switch and then 2 cm³ ofadditional water are added to the product via syringe. The latheringtechnique is then performed as described for liquid products after a 10second waiting time.

As used herein, the terms “substantially non-lathering” and“non-lathering” are used to mean a lather volume of from 0 ml to 20 ml.

Fibrous Structures—Fiber Diameter

For fibrous Structures, the diameter of dissolvable fibers in a sampleof a web is determined by using a Scanning Electron Microscope (SEM) oran Optical Microscope and image analysis software. A magnification of200 to 10,000 times is chosen such that the fibers are suitably enlargedfor measurement. When using the SEM, the samples are sputtered with goldor a palladium compound to avoid electric charging and vibrations of thefibers in the electron beam. A manual procedure for determining thefiber diameters is used from the image (on monitor screen) taken withthe SEM or the optical microscope. Using a mouse and a cursor tool, theedge of a randomly selected fiber is sought and then measured across itswidth (i.e., perpendicular to fiber direction at that point) to theother edge of the fiber. A scaled and calibrated image analysis toolprovides the scaling to get actual reading in microns (μm). Severalfibers are thus randomly selected across the sample of the web using theSEM or the optical microscope. At least two specimens from the web (orweb inside a product) are cut and tested in this manner. Altogether atleast 100 such measurements are made and then all data are recorded forstatistic analysis. The recorded data are used to calculate average(mean) of the fiber diameters, standard deviation of the fiberdiameters, and median of the fiber diameters. Another useful statisticis the calculation of the amount of the population of fibers that isbelow a certain upper limit. To determine this statistic, the softwareis programmed to count how many results of the fiber diameters are belowan upper limit and that count (divided by total number of data andmultiplied by 100%) is reported in percent as percent below the upperlimit, such as percent below 1 micron diameter or %-submicron, forexample. We denote the measured diameter (in microns) of an individualcircular fiber as d_(i).

In case the fibers have non-circular cross-sections, the measurement ofthe fiber diameter is determined as and set equal to the hydraulicdiameter which is four times the cross-sectional area of the fiberdivided by the perimeter of the cross of the fiber (outer perimeter incase of hollow fibers). The number-average diameter, alternativelyaverage diameter is calculated as, d_(num)

$\frac{\sum\limits_{i = 1}^{n}d_{i}}{n}$

Non-Limiting Examples

Comp. Comp. Ingredient Ex 1 Ex 2 Ex 3 Ex 4 Ex 5 Ex 6 Ex 7 Ex A Ex BDistilled Water 4.38 4.38 4.38 4.38 4.38 4.38 4.38 4.38 4.38 SodiumBenzoate, NF 0.27 0.27 0.27 0.27 0.27 0.27 0.27 0.27 0.27 Guar 0.80 0.800.80 0.80 0.80 0.80 0.80 0.80 0.80 hydroxypropyltrimonium Chloride¹Polyquatenium76² 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15 PolyvinylAlcohol³ 10.2 10.2 10.2 10.2 10.2 10.2 10.2 10.2 10.2 Polyvinyl Alcohol⁴10.2 10.2 10.2 10.2 10.2 10.2 10.2 10.2 10.2 Lauryl Hydroxysultaine⁵10.3 10.3 10.3 10.3 10.3 10.3 10.3 10.3 10.3 Sodium Chloride 1.8 1.8 1.81.8 1.8 1.8 1.8 1.8 1.8 Sodium Laureth 1 18.8 18.8 18.8 18.8 18.8 18.818.8 18.8 18.8 Sulfate Sodium Laureth 3 2.6 2.6 2.6 2.6 2.6 2.6 2.6 2.62.6 Sulfate Sodium Undecyl 11.6 11.6 11.6 11.6 11.6 11.6 11.6 11.6 11.6Sulfate Amodimethicone⁶ 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 Fragrance6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5 Sodium bicarbonate 9.1 9.1 9.1 9.19.1 9.1 9.1 9.1 9.1 Citric Acid, Anhydous 8.8 8.8 8.8 8.8 8.8 8.8 8.88.8 8.8 (Global) thickness (mm) 3.06 4.37 4.78 4.56 4.84 3.61 4.41 5.665.45 Basis Weight (g/m²) 939 1422 1443 1443 1432 1109 1477 1958 1958Number of Layers 2 3 3 3 4 3 3 4 4 Surfactant dose (g) 0.82 1.25 1.271.27 1.26 1.30 1.73 1.72 1.72 Total article density 0.346 0.366 0.3390.355 0.333 0.344 0.375 0.388 0.403 (g/cm3) surfactant density 0.1560.165 0.154 0.161 0.151 0.156 0.170 0.176 0.183 (g/cm3) Pad Footprint17.28 17.28 17.28 17.28 17.28 23.05 23.05 17.28 17.28 Total Pad weight(g) 1.83 2.76 2.80 2.80 2.78 2.86 3.81 3.79 3.79 hand dissolution 8 208.7 13.3 9.3 10 21.3 29.3 30 ¹Jaguar C500 supplied by Solvay ²MirapolAM-T supplied by Solvay ³PVA420H supplied by Kuraray ⁴PVA403 supplied byKuraray ⁵Mackham LHS supplied by Solvay ⁶Y-14945 Amino Fluid supplied byMomentive ⁷Neodol 25-3 supplied by Shell ⁸Tween-80 supplied by Croda

Examples/Combinations

Paragraph A: A dissolvable solid structure comprising fibers wherein thefibers are formed from a composition comprising:

-   -   a. from about 10% to about 75% of a surfactant;    -   b. from about 10% to about 70% water soluble polymeric        structurant;        wherein the dissolvable solid structure comprises a detersive        surfactant from about 0.5 g to about 4.0 g, has a detersive        surfactant density from about 0.1 to about 0.3 g/cm³; the bulk        density of the dissolvable solid structure is from about 0.100        to about 0.380 g/cm³, the dissolvable solid structure weight is        from about 1.0 g to about 4.0 g, and wherein the footprint of        the dissolvable solid structure is from about 1 cm² to about 50        cm².

Paragraph B: The dissolvable solid structure of Paragraph A, having adissolution of less than 25 strokes.

Paragraph C: The dissolvable solid structure of Paragraph A-B, whereinthe dissolvable solid structure contains detersive surfactant from about0.8 g to about 2 g.

Paragraph D: The dissolvable solid structure of Paragraph A-C, whereinthe dissolvable solid structure contains detersive surfactant from about0.9 g to about 1.5 g.

Paragraph E: The dissolvable solid structure of Paragraph A-D, whereinthe dissolvable solid structure contains detersive surfactant from about1.0 g to about 1.4 g.

Paragraph F: The dissolvable solid structure of Paragraph A-E, whereinthe dissolvable solid structure has a detersive surfactant density fromabout 0.1 g/cm³ to about 0.3 g/cm³.

Paragraph G: The dissolvable solid structure of Paragraph A-F, whereinthe dissolvable solid structure has a detersive surfactant density fromabout 0.12 g/cm³ to about 0.25 g/cm^(3.)

Paragraph H: The dissolvable solid structure of Paragraph A-G, whereinthe dissolvable solid structure has a detersive surfactant density fromabout 0.15 g/cm³ to about 0.18 g/cm³.

Paragraph I: The dissolvable solid structure of Paragraph A-H, whereinthe footprint of the dissolvable solid structure is from about 10 cm² toabout 50cm².

Paragraph J: The dissolvable solid structure of Paragraph A-I, whereinthe footprint of the dissolvable solid structure is from about 17 cm² toabout 23cm².

Paragraph K: The dissolvable solid structure of Paragraph A-J, whereinthe wherein the bulk density of the dissolvable solid structure is fromabout 0.100 g/cm³ to about 0.375 g/cm³.

Paragraph L: The dissolvable solid structure of Paragraph A-K, whereinthe wherein the bulk density of the dissolvable solid structure is fromabout 0.300 g/cm³ to about 0.375 g/cm³.

Paragraph M: The dissolvable solid structure of Paragraph A-L, whereinthe dissolvable solid structure has a basis weight of from about 400g/m2 to about 1800 g/m2.

Paragraph N: The dissolvable solid structure of Paragraph A-M, whereinthe dissolvable solid structure has a basis weight of from about 400g/m2 to about 1750 g/m2.

Paragraph O: The dissolvable solid structure of Paragraph A-N, whereinthe dissolvable solid structure has a basis weight of from about 400g/m2 to about 1650 g/m².

Paragraph P: The dissolvable solid structure of Paragraph A-O,comprising soluble polymeric structurant at from about 10% to about 30%by weight.

Paragraph Q: The dissolvable solid structure of Paragraph A-P,comprising soluble polymeric structurant at from about 15% to about 20%by weight.

Paragraph R: The dissolvable solid structure of Paragraph A-Q, whereinthe soluble polymeric structurant is polyvinyl alcohol.

Paragraph S: The Dissolvable Solid Structure of Paragraph A-R, whereinthe Dissolvable Solid Structure dissolves in less than about 15 strokesof the Hand Dissolution Method.

Paragraph T: The Dissolvable Solid Structure of Paragraph A-S, whereinthe dissolvable solid structure comprises fibers having an averagediameter less than about 20 micrometer.

Paragraph U: The Dissolvable Solid Structure of Paragraph A-T, whereinthe Dissolvable Solid Structure is a personal care article selected fromthe group consisting of hand cleansing Structures, hair shampoo, hairconditioner, hair color treatment Structures, facial cleansingStructures, body cleansing Structures, shaving preparation Structures,dental care Structures, personal care Structures containingpharmaceutical or other skin care active, moisturizing Structures,sunscreen Structures, chronic skin benefit agent Structures,vitamin-containing Structures, alpha-hydroxy acid-containing Structures,deodorizing Structures, fragrance-containing Structures, andcombinations thereof.

Paragraph V: The Dissolvable Solid Structure of Paragraph A-U, whereinthe Dissolvable Solid Structure further comprises one or more activeagents selected from the group consisting of, skin treatment actives,heat generating agents, color indicators, silicones, organicconditioning oils, perfumes, flavors, sensates, sweeteners, oral careactives, and combinations thereof.

Paragraph W: The Dissolvable Solid Structure of Paragraph A-V, whereinthe one or more water soluble polymeric structurants selected from thegroup consisting of polyalkylene oxides, polyvinyl alcohols,polyacrylates, copolymers of acrylic acid and methacrylic acid,polyvinylpyrrolidones, starch and starch derivatives, pullulan, gelatin,hydroxypropylmethylcelluloses, methylcelluloses, carboxymethycelluloses,salts and combinations thereof.

Paragraph X: The Dissolvable Solid Structure of Paragraph A-W, whereinthe one or more water soluble polymeric structurants has aweight-average molecular weight of from about 40,000 g/mol to about500,000 g/mol.

Paragraph Y: The Dissolvable Solid Structure of Paragraph A-X, whereinthe dissolvable solid structure comprises a mixture of fibers producedby one or more methods, wherein the fibers are mixed homogenously or inlayers.

Paragraph Z: The dissolvable solid structure of Paragraph A-Y,comprising from about 1 wt % to about 80 wt % preformed effervescentagglomerated particles.

Paragraph AA: The dissolvable solid structure of Paragraph A-Z,comprising from about 5 wt % to about 25 wt % preformed effervescentagglomerated particles.

Paragraph BB: The dissolvable solid structure of Paragraph A-AA, whereinthe detersive surfactant is an anionic surfactant selected from thegroup consisting of ammonium lauryl sulfate, ammonium laureth sulfate,triethylamine lauryl sulfate, triethylamine laureth sulfate,triethanolamine lauryl sulfate, triethanolamine laureth sulfate,monoethanolamine lauryl sulfate, monoethanolamine laureth sulfate,diethanolamine lauryl sulfate, diethanolamine laureth sulfate, lauricmonoglyceride sodium sulfate, sodium lauryl sulfate, sodium laurethsulfate, potassium lauryl sulfate, potassium laureth sulfate, sodiumlauryl sarcosinate, sodium lauroyl sarcosinate, lauryl sarcosine, cocoylsarcosine, ammonium cocoyl sulfate, ammonium lauroyl sulfate, sodiumcocoyl sulfate, sodium lauroyl sulfate, potassium cocoyl sulfate,potassium lauryl sulfate, triethanolamine lauryl sulfate,triethanolamine lauryl sulfate, monoethanolamine cocoyl sulfate,monoethanolamine lauryl sulfate, sodium tridecyl benzene sulfonate,sodium dodecyl benzene sulfonate, sodium cocoyl isethionate andcombinations thereof.

Note that any actives and/or compositions disclosed herein can be usedin and/or with the Structure, disclosed in the following U.S PatentApplications, including any publications claiming priority thereto: U.S.61/229,981; U.S. 61/229,986; U.S. 61/229,990; U.S. 61/229,996; U.S.61/230,000; and U.S. 61/230,004.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A dissolvable fibrous structure comprising aplurality of meltblown dissolvable fibrous elements wherein the fibrouselements are formed from a fibrous element-forming composition and thefibrous elements comprise: a. from about 10% to about 75% of an activewherein the active comprises a surfactant; b. from about 14% to about70% of a fibrous element-forming material consisting of one or morewater soluble polymeric structurants;  wherein the fibrous elementscomprise from about 0.5 g to about 4.0 g surfactant; wherein thedissolvable fibrous structure comprises: a surfactant density from about0.1 g/cm³ to about 0.3 g/cm³; a bulk density of the dissolvable fibrousstructure is from about 0.100 g/cm³ to about 0.380 g/cm³; a weight fromabout 1.0 g to about 4.0 g; a footprint from about 1 cm² to about 50cm²; wherein the fibrous elements comprise filaments; wherein theplurality of fibrous elements are inter-entangled or otherwiseassociated with one another to form the fibrous structure.
 2. Thedissolvable fibrous structure of claim 1, wherein the fibrous elementscomprise from about 0.8 g to about 2 g surfactant.
 3. The dissolvablefibrous structure of claim 2, wherein the fibrous elements comprise fromabout 0.9 g to about 1.5 g surfactant.
 4. The dissolvable fibrousstructure of claim 3, wherein the fibrous elements comprise from about1.0 g to about 1.4 g surfactant.
 5. The dissolvable fibrous structure ofclaim 1, wherein the surfactant density is from about 0.12 g/cm³ toabout 0.25 g/cm^(3.)
 6. The dissolvable fibrous structure of claim 5,wherein the surfactant density is from about 0.15 g/cm³ to about 0.18g/cm³.
 7. The dissolvable fibrous structure of claim 1, wherein thefootprint of the dissolvable solid fibrous structure is from about 10cm² to about 50 cm².
 8. The dissolvable fibrous structure of claim 8,wherein the footprint of the dissolvable solid fibrous structure is fromabout 17 cm² to about 23 cm².
 9. The dissolvable fibrous structure ofclaim 1, wherein the wherein the bulk density of the dissolvable solidfibrous structure is from about 0.100 g/cm³ to about 0.375 g/cm³. 10.The dissolvable fibrous structure of claim 1, wherein the wherein thebulk density of the dissolvable solid fibrous structure is from about0.300 g/cm³ to about 0.375 g/cm³.
 11. The dissolvable fibrous structureof claim 1, wherein the dissolvable solid fibrous structure furthercomprises a basis weight of from about 400 g/m² to about 1800 g/m². 12.The dissolvable fibrous structure of claim 1, wherein the dissolvablesolid fibrous structure further comprises a basis weight of from about400 g/m² to about 1750 g/m².
 13. The dissolvable fibrous structure ofclaim 1, wherein the dissolvable solid fibrous structure furthercomprises a basis weight of from about 400 g/m² to about 1650 g/m². 14.The dissolvable fibrous structure of claim 1, comprising one or moresoluble polymeric structurants at from about 10% to about 30% by weight.15. The dissolvable fibrous structure of claim 1, wherein thedissolvable solid structure dissolves in less than about 25 strokes ofthe hand dissolution method.
 16. The dissolvable fibrous structure ofclaim 15, wherein the dissolvable solid structure dissolves in less thanabout 15 strokes of the hand dissolution method.
 17. The dissolvablefibrous structure of claim 1, wherein at least 50% of the fibrouselements comprise a diameter of less than 150 microns.
 18. Thedissolvable fibrous structure of claim 1, wherein the dissolvable solidfibrous structure is a hair conditioner and wherein the surfactantcomprises a cationic surfactant.
 19. The dissolvable fibrous structureof claim 1, wherein the one or more water soluble polymeric structurantsis selected from the group consisting of polyalkylene oxides, polyvinylalcohols, polyacrylates, copolymers of acrylic acid and methacrylicacid, polyvinylpyrrolidones, polyvinyl methyl ether, polyvinylformamide, poly acrylamide, starch and starch derivatives, pullulan,gelatin, hydroxypropylmethylcelluloses, methylcelluloses,carboxymethycelluloses, salts and combinations thereof.
 20. Adissolvable fibrous structure comprising a plurality of meltblowndissolvable fibrous elements wherein the fibrous elements are formedfrom a fibrous element-forming composition and the fibrous elementscomprise: a. from about 25% to about 65% of an active wherein the activecomprises a cationic surfactant; b. a fatty alcohol; c. from about 14%to about 30% of a fibrous element-forming material;  wherein the fibrouselements comprise from about 0.5 g to about 4.0 g cationic surfactant;wherein the dissolvable fibrous structure comprises: a plurality ofapertures extending from a top surface to the bottom surface; asurfactant density from about 0.13 g/cm³ to about 0.3 g/cm³; a bulkdensity of the dissolvable fibrous structure is from about 0.100 g/cm³to about 0.380 g/cm³; a weight from about 1.0 g to about 4.0 g; afootprint from about 1 cm² to about 50 cm²; wherein the fibrous elementscomprise filaments; wherein the plurality of fibrous elements areinter-entangled or otherwise associated with one another to form thefibrous structure; wherein the fibrous structure is a conditionercomposition.